U.S. patent number 7,561,200 [Application Number 10/899,511] was granted by the patent office on 2009-07-14 for apparatus and method for automation of imaging and dynamic signal analyses.
This patent grant is currently assigned to CSI Technology, Inc.. Invention is credited to Raymond E. Garvey, III, Mark Granger, Anthony J. Hayzen, Michael D. Rich.
United States Patent |
7,561,200 |
Garvey, III , et
al. |
July 14, 2009 |
Apparatus and method for automation of imaging and dynamic signal
analyses
Abstract
A method and apparatus for inspecting equipment using focal
plane array imaging sensor data and dynamic sensor data. Methods
involve capturing focal plane array imaging sensor data using a
focal plane array imaging sensor such as an infrared camera or a
visible camera, or acquiring imaging sensor data from an electronic
data storage source, and involve capturing dynamic sensor data,
such as vibration or ultrasonic data using a dynamic sensor such as
an accelerometer or ultrasound system. Methods also provide for
analyzing imaging and dynamic sensor data using such techniques as
thermography and fast fourier transformation. Apparatuses include a
portable instrument with sensor interfaces for collecting imaging
sensor data and dynamic sensor data. A sensor suite is provided
that includes vibration sensor, sonic sensors, ultrasonic sensors,
oil sensors, flux sensors and current sensors. A base station is
included to collect and analyze data from one or more portable
instruments.
Inventors: |
Garvey, III; Raymond E.
(Loudon, TN), Rich; Michael D. (Powell, TN), Hayzen;
Anthony J. (Knoxville, TN), Granger; Mark (Knoxville,
TN) |
Assignee: |
CSI Technology, Inc.
(Wilmington, DE)
|
Family
ID: |
35656717 |
Appl.
No.: |
10/899,511 |
Filed: |
July 26, 2004 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20060017821 A1 |
Jan 26, 2006 |
|
Current U.S.
Class: |
348/333.01;
702/184; 73/570 |
Current CPC
Class: |
H04N
5/77 (20130101); H04N 17/002 (20130101); H04N
5/765 (20130101); H04N 5/775 (20130101); G01H
1/12 (20130101); G01H 17/00 (20130101) |
Current International
Class: |
H04N
5/222 (20060101); G01H 17/00 (20060101); G01N
24/00 (20060101); G06F 11/30 (20060101); G21C
17/00 (20060101) |
Field of
Search: |
;73/592 ;702/33,184
;348/333.01 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
US Infrared Incorporated, Thermoviewer, "A Maintenance System for
the 21st Century", (2 pp.). cited by other .
Tracking Analyzer Balancer System, DI-137, Dynamic Instruments, San
Diego, CA, www.dynamicinst.com (2 pages). cited by other .
WT Blademaster, Swangate International, www.swangate.com (1 page).
cited by other .
Delivering Machine Intelligence, "DLI Watchman.RTM. DCX.TM.
Hammerhead, Portable Vibration Data Collector & Machine
Diagnostic Analyzer", .COPYRGT. 2003--DLI Engineering Corporation,
www.dliengineering.com. cited by other .
Walkabout,
www.walkabout-comp.com/products.sub.--specs.sub.--port.html, Jul.
12, 2004. cited by other.
|
Primary Examiner: Ometz; David L
Assistant Examiner: Jerabek; Kelly L
Attorney, Agent or Firm: Luedeka, Neely & Graham,
P.C.
Claims
What is claimed is:
1. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising thermographic
image data from the imaging sensor data using at least a portion of
the application instructions; deriving at least one dynamic
indication of equipment health comprising an ultrasonic dB value
from the dynamic sensor data using at least the dynamic signal
analysis portion of the application instructions, wherein the at
least one imagery indication of equipment health and the at least
one dynamic indication of equipment health are derived from the
imaging sensor data and the dynamic sensor data that were acquired
at approximately the same time; and correlating the thermographic
image data with the ultrasonic dB value to assess performance of a
valve.
2. The method of claim 1 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
3. The method of claim 1 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
4. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
and (b) application instructions for receiving, storing, and
analyzing dynamic sensor data to derive at least one dynamic
indication of equipment health wherein the analyzing dynamic sensor
data includes one or more analyzing techniques selected from the
following group: Fast Fourier Transform (FFT) vibration analysis,
waveform vibration analysis, spectral vibration analysis, stress
wave analysis, transient analysis, sonic analysis, ultrasonic
analysis, FFT flux analysis, and FFT current analysis, and (c)
application instructions for correlating at least one imagery
indication of equipment health with at least one dynamic indication
of equipment health; while on a route or survey, receiving and
storing focal plane array imaging sensor data and dynamic sensor
data in the portable instrument using at least a portion of the
application instructions; deriving at least one imagery indication
of equipment health comprising a thermal indication from the
imaging sensor data using at least a portion of the application
instructions; deriving at least one dynamic indication of equipment
health from the dynamic sensor data using at least the dynamic
signal analysis portion of the application instructions; and while
on the route or survey, isolating a fault from a normal condition
using both the imagery indication and the dynamic sensor indication
to conclude whether the thermal indication likely indicates a
normal condition or an abnormal condition.
5. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising an infrared
image showing relatively hot coupling from the imaging sensor data
using at least a portion of the application instructions; deriving
at least one dynamic indication of equipment health comprising
vibration analysis from the dynamic sensor data using at least the
dynamic signal analysis portion of the application instructions,
wherein the at least one imagery indication of equipment health and
the at least one dynamic indication of equipment health are derived
from the imaging sensor data and the dynamic sensor data that were
acquired at approximately the same time; and correlating the
infrared image showing relatively hot coupling with vibration
analysis results to assess hardware misalignment.
6. The method of claim 5 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
7. The method of claim 5 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
8. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising
delta-temperature data from the imaging sensor data using at least
a portion of the application instructions; deriving at least one
dynamic indication of equipment health comprising heterodyned
ultrasonic sounds from the dynamic sensor data using at least the
dynamic signal analysis portion of the application instructions,
wherein the at least one imagery indication of equipment health and
the at least one dynamic indication of equipment health are derived
from the imaging sensor data and the dynamic sensor data that were
acquired at approximately the same time; and correlating the
delta-temperature data with the heterodyned ultrasonic sounds to
assess a power line insulator connection.
9. The method of claim 8 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
10. The method of claim 8 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
11. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising a bore scope
image from the imaging sensor data using at least a portion of the
application instructions; deriving at least one dynamic indication
of equipment health comprising a vibration spectrum from the
dynamic sensor data using at least the dynamic signal analysis
portion of the application instructions, wherein the at least one
imagery indication of equipment health and the at least one dynamic
indication of equipment health are derived from the imaging sensor
data and the dynamic sensor data that were acquired at
approximately the same time; and correlating the bore scope image
with the vibration spectrum to characterize gear or bearing
components.
12. The method of claim 11 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
13. The method of claim 11 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
14. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising image data
from the imaging sensor data using at least a portion of the
application instructions; deriving at least one dynamic indication
of equipment health comprising vibration data from the dynamic
sensor data using at least the dynamic signal analysis portion of
the application instructions, wherein the at least one imagery
indication of equipment health and the at least one dynamic
indication of equipment health are derived from the imaging sensor
data and the dynamic sensor data that were acquired at
approximately the same time; and correlating image and vibration
data before and after thermal growth to evaluate misalignment.
15. The method of claim 14 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
16. The method of claim 14 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
17. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising a
thermographic image from the imaging sensor data using at least a
portion of the application instructions; deriving at least one
dynamic indication of equipment health comprising ultrasonic leak
detection from the dynamic sensor data using at least the dynamic
signal analysis portion of the application instructions, wherein
the at least one imagery indication of equipment health and the at
least one dynamic indication of equipment health are derived from
the imaging sensor data and the dynamic sensor data that were
acquired at approximately the same time; and correlating the
ultrasonic leak detection with the thermographic image to assess a
system containing compressed or heated gas.
18. The method of claim 17 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
19. The method of claim 17 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
20. A method for inspecting equipment, the method comprising,
storing in a portable instrument (a) application instructions for
receiving, storing and analyzing focal plane array imaging sensor
data to derive at least one imagery indication of equipment health,
(b) application instructions for receiving, storing, and analyzing
dynamic sensor data to derive at least one dynamic indication of
equipment health wherein the analyzing dynamic sensor data includes
one or more analyzing techniques selected from the following group:
Fast Fourier Transform (FFT) vibration analysis, waveform vibration
analysis, spectral vibration analysis, stress wave analysis,
transient analysis, sonic analysis, ultrasonic analysis, FFT flux
analysis, and FFT current analysis, and (c) application
instructions for correlating at least one imagery indication of
equipment health with at least one dynamic indication of equipment
health; while on a route or survey, receiving and storing focal
plane array imaging sensor data and dynamic sensor data at
approximately the same time in the portable instrument using at
least a portion of the application instructions; deriving at least
one imagery indication of equipment health comprising a relatively
hot location on a thermogram from the imaging sensor data using at
least a portion of the application instructions; deriving at least
one dynamic indication of equipment health comprising an ultrasonic
signature from the dynamic sensor data using at least the dynamic
signal analysis portion of the application instructions, wherein
the at least one imagery indication of equipment health and the at
least one dynamic indication of equipment health are derived from
the imaging sensor data and the dynamic sensor data that were
acquired at approximately the same time; and correlating the
imagery indication of equipment health with the dynamic indication
of equipment health to verify that the infrared indication of
equipment health indicates heating caused by friction.
21. The method of claim 20 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing focal plane array imaging sensor data comprises storing
in an instrument application instructions for receiving, storing
and analyzing focal plane array infrared imaging sensor data, and
the step of receiving and storing focal plane array imaging sensor
data in the instrument comprises receiving and storing focal plane
array infrared imaging sensor data in the instrument.
22. The method of claim 20 wherein the step of storing in an
instrument application instructions for receiving, storing and
analyzing dynamic sensor data comprises storing in an instrument
application instructions for receiving, storing and analyzing
dynamic sensor data using FFT analysis, and the step of deriving at
least one dynamic indication of equipment health comprises deriving
at least one dynamic indication of equipment health using FFT
analysis.
Description
FIELD
This invention pertains to an apparatus for detecting and analyzing
equipment operational parameters. More particularly the invention
pertains to apparatuses for imaging and dynamic signal analysis for
monitoring the status of equipment health. Imaging devices include
focal plane array devices that sense infrared or visible light.
Dynamic signal analysis devices include vibration or ultrasonic
detectors.
BACKGROUND
Infrared imagers are commonly used for thermographic inspections of
equipment. State of the art for infrared inspection process
involves use of an uncooled, radiometric, focal plane array,
infrared camera plus visible camera built into a lightweight,
hand-held package with onboard digital memory, an LCD display, and
interactive user interface. Visible light imaging systems are also
used for inspection of equipment. Examples of such applications are
borescopes, fiberscopes, and even conventional video cameras.
Various dynamic measurement systems have also been developed to
monitor the operational health of equipment. Examples of such
systems are vibration analysis devices, sonic or ultrasonic
measurement devices, and electromagnetic spectrum analyzers In
addition, various devices have been developed for measurement of
conditions that are often more static in nature, such as
temperature, pressure, and lubrication properties.
Typically, vibration analysis and infrared analysis have been
handled as distinct and separate condition monitoring techniques
with regard to walk-around inspections, routes, or surveys. The
maintenance departments of industrial plants have employed totally
separate devices for each different condition monitoring method.
For example a typical industrial plant often uses an infrared
camera for infrared inspection, a multi-frequency sonic and
ultrasonic inspection system for acoustic monitoring, a videoscope
for video inspection, a minilab oil analyzer for on-site oil
analysis, and a fast Fourier transform (FFT) equipment analyzer for
vibration, flux, and current analysis.
Existing technology does not adequately address all of the needs
for integrating the collection of imaging information with other
sensor measurements. What is needed is a system that provides
portable imaging capability with portable dynamic sensor
measurement capability plus optionally portable static measurement
capability.
SUMMARY
With regard to the above, in one of its embodiments the invention
provides a portable instrument for inspecting equipment. The
portable instrument includes a first sensor interface for a focal
plane array imaging sensor, where the first sensor interface
includes electro-mechanics configured to receive imaging sensor
data. The portable instrument also includes a second sensor
interface for a dynamic sensor, where the second sensor interface
includes electro-mechanics configured to receive dynamic sensor
data. Further, the portable instrument incorporates a digital
memory that stores an operating system and application instructions
and a dataset. A processor is proved that runs the operating system
and is operatively connected to the digital memory and operatively
connected to the first sensor interface and is operatively
connected to the second sensor interface. The processor is
configured to use at least a portion of the application
instructions for recording in the dataset at least a portion of
imaging sensor data and for recording in the dataset at least a
portion of dynamic sensor data. The processor is further configured
to use at least a portion of the application instructions to
operate on the imaging sensor data and to derive at least one
dynamic indication of equipment health. Additionally, the portable
instrument has a display that presents information; and a user
interface that in cooperation with the processor controls what
information is presented on the display.
Alternate embodiment provides a portable apparatus for inspecting
equipment that includes a first sensor interface for a focal plane
array imaging sensor, where the first sensor interface includes
electro-mechanics configured to receive imaging sensor data, and a
second sensor interface for a dynamic sensor, where the second
sensor includes electro-mechanics configured to receive dynamic
sensor data. The portable apparatus also incorporates a processor
operatively connected to the first sensor interface and operatively
connected to the second sensor interface and configured with an
application instruction for analyzing the dynamic sensor data and
for deriving at least one dynamic indication of equipment health,
and a display that presents information, and a user interface that
in cooperation with the processor controls what information is
presented on the display. The portable apparatus also incorporates
a focal plane array imaging sensor that is operatively connected to
the first sensor interface for sending imaging sensor data to the
first sensor interface, and a dynamic sensor that is operatively
connected to the second sensor interface for sending dynamic data
to the second sensor interface.
A further alternate embodiment is an apparatus for inspecting
equipment that includes a portable instrument and a base station.
The portable instrument incorporates a first sensor interface for a
focal plane array imaging sensor, where the first sensor interface
includes electro-mechanics configured to receive imaging sensor
data, and a second sensor interface for a dynamic sensor, where the
second sensor includes electro-mechanics configured to receive
dynamic sensor data. The portable instrument also incorporates a
processor operatively connected to the first sensor interface and
operatively connected to the second sensor interface, plus a
display that presents information, a user interface that in
cooperation with the processor controls what information is
presented on the display, and a wireless transmitter that is
configured cooperatively with the processor to transmit at least a
portion of the imaging sensor data and at least a portion of the
dynamic sensor data. The a base station has a wireless receiver
configured to receive at least a portion of imaging sensor data and
at least a portion of dynamic sensor data transmitted by the
transmitter in the portable instrument. The base station also
includes a central processor that is operatively connected to the
receiver, a station display that presents information, and a
station user interface that in cooperation with the central
processor controls what information is presented on the station
display.
A different embodiment presents a method for inspecting equipment
that involves storing in an instrument (a) application instructions
for receiving, storing and analyzing focal plane array imaging
sensor data to derive at least one imagery indication of equipment
health, and (b) application instructions for receiving, storing,
and analyzing dynamic sensor data to derive at least one dynamic
indication of equipment health, and (c) application instructions
for correlating at least one imagery indication of equipment health
with at least one dynamic indication of equipment health. The
method continues with receiving and storing focal plane array
imaging sensor data and dynamic sensor data in the instrument using
at least a portion of the application instructions, deriving at
least one imagery indication of equipment health using at least a
portion of the application instructions, and deriving at least one
dynamic indication of equipment health using at least a portion of
the application instructions. The method concludes with the step of
correlating at least one imagery indication of equipment health
with at least one dynamic indication of equipment health.
A further alternate method embodiment is a method for inspecting
equipment that includes storing in an instrument application
instructions for capturing and transmitting imaging sensor data
from a focal plane array imaging sensor and application
instructions for capturing and transmitting waveforms from a
dynamic sensor, and storing in a base station application software
for (a) receiving, storing and analyzing imaging sensor data to
derive at least one imagery indication of equipment health, and (b)
application software for receiving, storing, and analyzing
waveforms to derive at least one dynamic indication of equipment
health, and (c) application software for correlating at least one
imagery indication of equipment health with at least one dynamic
indication of equipment health. The method includes a step of
capturing imaging sensor data with a focal plane array imaging
sensor and transmitting at least a portion of the imaging sensor
data from the instrument to the base station using at least a
portion of the application software. A further step is receiving
and storing in the base station at least a portion of the imaging
sensor data transmitted by the instrument using at least a portion
of the application software. The method includes capturing dynamic
sensor data with a dynamic sensor and transmitting at least a
portion of the dynamic sensor data from the instrument to a base
station using at least a portion of the application software, with
the further step of receiving and storing in the base station at
least a portion of the dynamic sensor data transmitted by the
instrument using at least a portion of the application software.
The method concludes with deriving at least one imagery indication
of equipment health using at least a portion of the application
software, and deriving at least one dynamic indication of equipment
health using at least a portion of the application software.
An alternative embodiment provides a system for inspecting
equipment. the system incorporates a portable instrument that
includes a focal plane array imaging sensor selected from selected
from the group consisting of (a) an infrared focal plane array
imaging sensor and (b) a visible focal plane array imaging, where
the focal plane array imaging sensor is configured to generate
imaging sensor data and a dynamic sensor selected from the group
consisting of (a) a vibration sensor and (b) a sonic sensor and (c)
an ultrasonic sensor and (d) a flux sensor and (e) a current
sensor, where the dynamic sensor configured to generate dynamic
sensor data. The portable instrument further includes digital
memory that stores an operating system and application instructions
and a dataset. The portable instrument has a processor that runs
the operating system and is operatively connected to the digital
memory and operatively connected to the imaging sensor and is
operatively connected to dynamic sensor. The processor is
configured to use at least a portion of the application
instructions for recording in the dataset at least a portion of the
imaging sensor data and for recording in the dataset at least a
portion of the dynamic sensor data. The processor is further
configured to use at least a portion of the application
instructions to operate on the imaging sensor data and the dynamic
sensor data stored in the dataset and to derive at least one
dynamic indication of equipment health. the portable instrument
also includes a display that presents at least a portion of the
imaging sensor data and presents at least a portion of the dynamic
sensor data. The portable instrument also has a user interface that
in cooperation with the processor controls what imaging sensor data
and what dynamic sensor data is presented on the display.
A further alternative embodiment provides a method for automating
inspection of an equipment item using both imaging and dynamic
signal analysis. The method begins with providing a
battery-operated inspection device having a processor, memory, a
display having at least one window data input, and a user
interface. The method proceeds with providing imaging data and
dynamic signal data for the equipment item to the processor. The
method also includes steps of using the processor to derive a
dynamic indication of equipment health based upon a least a portion
of the inputted dynamic signal data and using the processor to
establish an association data element. the method also includes a
step of providing a user interface selection to allow a user to
view at least a portion of the imaging data and at least a portion
of the dynamic indication of equipment health on at least one
window on the display while the user performs the inspection.
One advantage of these and other embodiments is the improved
ability to analyze the health of equipment. Incorporation of means
to gather data in the field is also important in some embodiments.
Other advantages of various embodiments include integrating the
functions of a portable instrument with a base station. Also, as
will be seen in the detailed description of various embodiments,
provisions for analyzing imaging sensor data and dynamic sensor
data are incorporated to meet previously identified needs. Finally,
embodiments are provided that incorporate combined analysis of
imaging sensor data and dynamic sensor data thereby enhancing the
overall versatility and utility of various embodiments for
maintenance and preventive maintenance operations.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention are apparent by reference to
the detailed description when considered in conjunction with the
figures, which are not to scale so as to more clearly show the
details, wherein like reference numbers indicate like elements
throughout the several views, and wherein:
FIG. 1 is a block diagram of a multiple sensor system.
FIG. 2 is a depiction of switchgear in a switchyard.
FIG. 3 is a schematic representation of a portable platform front
view.
FIG. 4 is a schematic representation of a portable platform back
view.
FIG. 5 is a flow chart of one method embodiment.
FIG. 6 is a flow chart of an alternate method embodiment.
FIG. 7 is a flow chart of a further alternate method
embodiment.
DETAILED DESCRIPTION
The present invention provides an apparatus for efficiently
identifying and analyzing concerns possibly requiring maintenance
for various types of equipment and machinery such as power
circuits, transformers, switchgear, motor control centers, motors,
pumps, fans, presses, drive trains, gear boxes, etc. The term
"equipment" will be used and understood herein to include machinery
and to cover devices with moving part as well as devices without
moving parts. Many embodiments described herein allow for complex
analysis, including summation, of multiple signals representing
equipment characteristics through a plurality of sensors, and
provides the opportunity for economy, time savings and safety
through operation of a portable platform connected by contact or
wireless means to a both dynamic signal analysis and focal plane
array imaging sensors. A portable platform is a form of an
instrument.
The preferred embodiments employ a multiple-technology, highly
automated, portable inspection system that combines infrared
inspection with other portable condition monitoring
technologies.
One aspect of the most preferred embodiments is a portable platform
that the technician carries to the field. The portable platform
typically includes a processor with software constructed in a
housing. The portable platform generally also includes portable
display, portable power system, and data input and data output
capability. It has mouse or touch-screen or button or other user
interface capabilities for use by the field technician.
Another aspect of the most preferred embodiments of the portable
platform is the incorporation of at least one sensor interface in
the portable platform. A sensor interface typically comprises
electro-mechanics (hardware, firmware, or both) that are capable of
receiving data from a sensor and conveying the data to central
processing unit in portable platform so that the data may be stored
in electronic memory. In some embodiments, the sensor interface
also includes electro-mechanics for transmitting data from the
portable platform to the sensor. A sensor interface may also
incorporate electronics and firmware tools for translating signals
from a sensor into useful data. For example, a sensor interface may
include an analog to digital converter, a sampling circuit or
sampling software, a frame grabber, or a format conversion tool
such as hardware or software for converting NTSC or PAL video
signals to VGA or SVGA format for presentation on a display, or for
converting such signals to .jpg (or similar) files for storage in
an electronic memory. A sensor interface may also include data
authentication tools such as time stamping, encryption, and file
locking software, although such data authentication tools may
alternately be provided by application instructions that reside in
the electronic memory and are executed by the portable platform.
Some examples of a sensor interface are a video capture card, an
RS-232 serial port module, a parallel port, a universal serial bus
(USB) card, an analog interface adapter, an input/output card, and
a data acquisition board. In the most preferred embodiments, the
sensor interface is operatively connected to the housing of the
portable platform, meaning that is mechanically mounted and
electronically integrated with the other electronics.
Generally, sensor interfaces are designed to accommodate dynamic
sensor data. Dynamic sensor data represents information having a
time domain, meaning that the measurements detected by the sensor
vary over time and that variation is recorded from a start time to
an end time. However, sensor interfaces are often also designed to
accommodate static sensor data. Static sensor data represents
measurements taken at a single point in time.
Imaging techniques can include either infrared or visible detection
sensors having either analog or digital output. Infrared cameras
are often used as infrared imaging sensors and digital cameras are
often used as visible imaging sensors. In both cases the field of
view for the image describes an area of interest. Infrared imaging
includes both radiometric and non-radiometric type detector arrays.
Imaging may be individual frame or multiple frames. Imaging may
include enhancements by magnification, zoom, light amplification,
or optical wave guides, or other techniques. These images produced
by such imaging sensors are examples of imaging sensor data.
Typically image data analysis produces an array of values such as
emissivity or temperature or another imagery indication of
equipment health. Other imagery indications of equipment health may
include the following. Point value representation normally
associated with either the center pixel or a cursor. Maximum scalar
value determination. Minimum scalar value determination. Average
scalar value determination. Median scalar value determination.
Absolute or standard deviation scalar value representing a range of
values. Delta scalar value or differential determination. Contour
of scalar values or connection of pixels having similar values.
Alarm limit scalar values methods for distinguishing values inside
or outside of alarm conditions. Histogram showing statistical
profile representation of scalar values within a selected area.
Line profile showing scalar values corresponding to a linear path
on the image Other individual, differential, or statistical
analysis of scalar values with or without considering pixel
position. Distance in pixels or other dimensional units between
features on the image. Number(s) of item(s) with particular
characteristics on at least a portion of the image. Classification
of characteristics of object(s) in the image based on particular
visual characteristics. Comparison of image being analyzed with one
or more reference imaging sensor data. Results of parametric
analysis of the image using a digital image analysis software tool.
Results of parametric analysis using other graphical image analysis
tools.
Dynamic sensors typically employ devices such as accelerometers,
piezoelectric components, electrical current or voltage probes,
thermocouples, pitot tubes, and sonic or ultrasonic detectors.
Dynamic analysis or dynamic signal analysis techniques include, but
are not limited to Fast Fourier Transform (FFT) vibration analysis,
waveform vibration analysis, spectral vibration analysis, stress
wave analysis, transient analysis, sonic analysis, ultrasonic
analysis, FFT flux analysis, and FFT current analysis. Such
analysis generally produces one or more dynamic indications of
equipment health. Examples of dynamic indications of equipment
health are: Speed Overall value Less than one times turning speed
value One times turning speed value Two times turning speed value
Three to eight times turning speed value Nine to thirty-five times
turning speed value More than thirty-five times turning speed value
One times line frequency value Two times line frequency value 4 kHz
peak value 4 kHz average value 4 kHz peak hold value 30 kHz peak
value 30 kHz average value 30 kHz peak hold value 40 kHz peak value
40 kHz average value 40 kHz peak hold value 150 kHz peak value 150
kHz average value 150 kHz peak hold value
The dynamic indications of equipment health are often associated
with particular locations or orientations. Here are some examples
of such particular locations or orientations: Motor outboard
horizontal Motor outboard vertical Motor outboard axial Motor
inboard horizontal Motor inboard vertical Pump inboard horizontal
Pump outboard horizontal Pump outboard axial Inlet Outlet Suction
Discharge X, Y, Z or other coordinate locator Angle or other
relative orientation
Many preferred embodiments provide for the correlating of imaging
analysis data and dynamic or static data analysis data. In a very
basic form, the correlating is accomplished by simply making both
imaging sensor data and dynamic or static data available
substantially simultaneously to a technician so that results can be
reviewed comparatively. Correlating data may also involve such
actions as adjusting scales to common units, identifying data sets
that pertain to the same equipment or measurements, matching
imaging sensor data files with dynamic sensor data files, and
performing multivariate analysis. In some instances this
correlating includes the calculation of one or more equipment
health combined statistics that are derived from a joint analysis
of imaging sensor data and dynamic/static data. Examples of
equipment health combined statistics are: Temperature of an
excessively vibrating bearing. Overlay of a thermal trend and a
vibration level trend. Viscosity of oil at the highest temperature
point in a machine. A plot of peak vibration versus temperature.
Amperage at hottest spot in a power line. Comparison of a thermal
image and an ultrasonic image. Dimensional location of hottest
point in a furnace. Thermographic image data and corresponding
ultrasonic dB values for inlet and outlet positions on a steam trap
or other valve. Infrared image showing fluid level, compared to
level sensor output showing same fluid level. Infrared image
showing relatively hot coupling verifying vibration analysis
results indicating misalignment. Visual image showing adhesive wear
indications from mixed mode or boundary lubrication compared to
elevated ultrasonic dB levels. Delta-temperature correlated with
heterodyned ultrasonic sounds from electrical discharge or corona
on power line insulator connections. Visual strobe imaging
synchronized with a vibration fault frequency. Bore scope image of
gear or bearing components identified by characteristic vibration
spectrum. Animation of an otherwise static visual image using data
from modal vibration analysis. Correlation of image and vibration
due to misalignment before and after thermal growth. Comparison of
ultrasonic dB levels with oil level. Verification that heat showing
up on a thermographic image is caused by increased friction due to
adhesive wear (e.g., boundary lubrication regime) by measuring
airborne ultrasonic signature in the vicinity of the relatively hot
location on the thermogram. Comparing data from wear debris image
analysis with PeakVue.RTM. vibration data. Correlation of
ultrasonic leak detection with thermographic image for a system
containing compressed or heated gas Validation of stator faults by
comparing thermographic image with motor flux analysis.
In integrating imaging and dynamic sensor data it is beneficial to
store to at least one association data element that identifies what
imaging sensor data is associated with what sensor data. In most
cases this association is the result of taking and recording both
the imaging sensor data and the sensor data related to a particular
piece of equipment at approximately the same time. However in some
cases the association may relate to changes that occur over time,
comparative information taken from multiple machines, or other
considerations. The association data elements may be established by
creating a data field in an independent database that links the
identity one or more image files with the identity of one or more
sensor data files. In other cases association data elements may be
established by creating matching data records in separate file
fields in both the image file(s) and the sensor data file(s) that
are associated with each other. One image file may be associated
with only one sensor data file, or one image file may be associated
with multiple sensor data files, or multiple image files may be
associated with one sensor data file. It is even possible that
multiple image files and multiple sensor data files are all
associated. Examples of association data elements are an electronic
date and time stamp, a job code identifier, an operator identifier,
a location identifier, a subject identifier, or even a random
number that ties both the imaging sensor data and the dynamic
sensor data together so that the two data sets are identified as
being associated with each other.
An example of combining imaging and associated analysis with
dynamic analysis in a portable system is the integration of
infrared thermography with portable vibration analysis. The
infrared focal plane array and vibration transducer are two of the
sensors from which the technician collects data while in the field
using the portable platform. This combination provides a view of
equipment health enabling fault isolation. Certain faults trigger
temperature changes, some trigger both temperature and vibration
signatures, and some trigger only vibration indications. Examples
are motor stator shorts, coupling faults, and imbalance
respectively. This method of using multiple techniques to view
equipment faults is called fault isolation.
The use of thermographic imaging allows the technician to survey a
large area on the machine in a rapid sweep, quickly locating hot or
cold sites. Temperature anomalies are easily identified with the
focal plane array technique that would likely have been missed
using point temperature measurements. Temperature excursions are
commonly associated with equipment faults. Embodiments that include
portable vibration analysis provide the technician with a further
beneficial tool to assess such equipment faults.
Another example of imaging and dynamic analysis is the integration
of infrared thermography with sonic or ultrasonic analysis. In this
case the infrared focal plane array and sonic or ultrasonic
transducers are two of the sensors from which the technician
collects data while in the field using the portable platform. The
term sonic sensor refers to a sensor that detects transmission
media waves at frequencies up to the top of the human audible
range, whereas the term ultrasonic sensor refers to a sensor that
detects transmission media waves above the top frequency of the
human audible range. Both ultrasonic and infrared focal plane array
technologies are well suited for area surveys. The combination
provides greater insight than use of either one independently. For
example, steam traps are best surveyed using both infrared and
sonic/ultrasonic measurements. The focal plane array is able to
identify steam flow and blow-by. Sonic and ultrasonic sensors are
able to identify performance of many mechanisms inside the steam
trap. The combination isolates faults and provides intuitive
insight as to normal versus abnormal operation. Certain traps are
faulty when steam is blowing by. For others this is normal. The
visible indication and ultrasonic signature allows the user to
fully understand the operation and interpret the normal or fault
condition. In the same way, ultrasonic and infrared are excellent
combined field technologies for electrical applications in which
corona, arcing, or discharge may occur. By understanding that
ultrasonic signature often indicates friction and sustained high
friction generates temperature excursions, the operator equipped
with a single platform including both measurements has the
advantage.
Still another aspect of some embodiments is the integration of
infrared thermography with oil analysis information collected while
on a route or survey. In this case the infrared focal plane array
and an oil sensor are two of the sensors from which the technician
collects data using the portable platform. Four of the common
equipment fault conditions revealed through lubricant analysis
include fatigue, abrasion, adhesion, and corrosion. Fault isolation
can be enhanced using the combination of infrared focal plane array
inspection with lubricant analysis. For example, adhesion often
results from inadequate lubrication which may be caused by low
viscosity. A viscosity sensor reporting low oil viscosity combined
with the presence of heat in load bearing regions provides an
indication of cause and effect. The viscosity sensor can be
installed in the machine with communication via cable or wireless
method, or the viscosity sensor can be transported to the equipment
by the operator.
Typically an oil sensor is a static sensor and the measured data
are static sensor data. Other examples of sensors that are normally
used as static sensors are pressure gages, temperature probes and
linear displacement gages.
The combination of three or four data analyses (e.g., oil analysis,
sonic/ultrasonic analysis, vibration analysis, and focal plane
array infrared analysis) may provide the operator with immediate
and accurate indication of equipment health that would not have
been derived by one or even two of the separate technologies. For
example, in the event that the oil level falls below critical level
causing the oil sensor to trigger "low oil" the resulting condition
can be a lubricant starved bearing condition with high ultrasonic
signature, high vibration as well as a temperature excursion. The
operator who observes this situation fills the oil level, noting
the return to normal oil level, normal sonic/ultrasonic signature,
normal temperature, and vibration signature with distinctly
quantified vibration faults and fault frequencies. The combination
allows a field operator to make an accurate assessment of the
equipment condition and effect of corrective actions.
Yet another aspect of the invention is the integration of infrared
thermography with bore-scope inspection while on a route or survey.
In this case the infrared focal plane array and the bore-scope are
two of the sensors from which the technician collects data using
the portable platform. In this case the infrared looks at the
outside surface temperature while the bore-scope interrogates the
inside aspects of a difficult to access volume containing critical
mechanisms.
A bore-scope is one example of a visible image sensor. A visible
image sensor is a sensor that detects light in the human visible
spectrum. Other examples of visible image sensors are camcorders,
optical microscope imagers, and digital cameras.
Typically, the technician will determine which measurements will
need to be made and carry only the items needed for a particular
survey. Sensors in the sensor suite may be carried by the
technician or may already be installed in the field
application.
Sensors may be connected by cable to the portable platform. An
alternative configuration is for the sensor to be in wireless
communication. Another alternative is for the sensor to collect
measurements in one operation and then transfer the data to the
portable platform in a second operation using electrical contacts
or wireless communication. Also a microphone recording device,
typically built into the portable platform, may be used to provide
voice annotation. A microphone is a specialized form audible
detector that is excluded from the general category of sonic
sensors.
Many embodiments incorporate a base computer that in preferred
embodiments consists of a personal computer with database and
application software, data input/output, and a printer. Either the
portable platform or the base computer or both can be part of a
network or server or internet application.
An aspect of preferred embodiments is a portable platform which may
include a processor (such as a central processing unit), display,
power supply, transmitter, user interface, database, application
instructions (firmware or software), and at least one sensor
interface. Often a personal computer is adapted to become the
computing portion of a portable platform. In some of these
embodiments the portable platform uses cables and electrical
contact to transmit data. In an alternate embodiment,
communications may be accomplished using wireless means such as
infrared or radio frequency or microwave. Such wireless
communications may be used between the portable platform and one or
more of the sensors. Wireless communications may also be used
between the portable platform and the host system. Generally the
application instructions loaded in the portable platform direct the
functioning of the unit. However in some cases some of the
software, database, and other functions may be equivalently
performed in the host or base platform instead of on the portable
platform by, for example, using networks, file servers, and so
forth.
An overarching theme of many embodiments is the ability to operate
on imaging sensor data and dynamic or static sensor data. Operating
on the data may include such actions as editing the data,
reformatting the data, adding annotations to the data,
simultaneously viewing image data and sensing data, correlating
data from the same sensor, correlating the data from different
sensors, or analyzing the data.
Referring now to FIGS. 1, 2, and 3, a sensor suite (122) is shown
to be in communication with a portable platform (123 and 207) to
perform condition monitoring analyses. Analysis is typically done
by a technician who walks a route or performs an area survey
carrying as a minimum the portable platform (123 and 207) and a
dynamic signal analysis sensor such as either a sonic sensor (118),
an ultrasonic sensor (117), a vibration sensor (119), a flux sensor
also called flux coil (115) or current sensor (114). In addition
the technician carries an imaging sensor such as the infrared
camera (121) or visible camera (120). Other devices such as an oil
sensor (116) may be used as well.
The infrared camera (121) is typically an uncooled focal plane
array type imager provides either a formatted digital signal or
analog video signal to the portable platform (123). In one
embodiment the ergonomically designed infrared imager (121) houses
the imaging optics, detector, drive electronics, optical modulator,
laser-pointer and four standard or rechargeable AA size batteries.
The infrared camera (121) is an example of an image sensor and the
output of the infrared camera is referred to as imaging sensor
data. In alternate embodiments a visible spectrum digital camera
may be the image sensor that produces the imaging sensor data.
Application instructions (109) (typically stored as software or
firmware) run on a processor (124) (such as a central processing
unit) under an operating system (141) (such as Windows CE.RTM.) in
the portable platform (123 and 207). The application instructions
(109) are used to interpret the analog or digital signal, present
this information on the portable display (125), and use the
processor (124) to save imaging sensor data (147A, 147B) in the
digital memory (140) of the portable platform (123 and 207). The
digital memory (140) may include read only memory, random access
memory, and media memory such as compact disc data storage.
A visible camera (120) may be integral with the infrared camera
(121) or may be independent. The visible camera may include
optional lighting accessories such as flash, it may include special
optics and wave guide accessories. An optical wave guide is
valuable for bore-scope inspection in hard to reach locations of
equipment. One embodiment for the visible camera (121) is a
point-and-shoot liquid crystal display camera. Another embodiment
uses a digital camera suitable for either live or still frame
photography including zoom-coupled smart auto-focus system,
automatic light guide zoom flash, and low-light features.
The one-way or two-way data transfer sensor communication link
(112) between the camera(s) (120, 121) and the portable platform
(123 and 207) may be rigid and attached; may be temporarily
attached; may be flexible, allowing reorientation different from
that of the portable platform; may be connected via cable; or may
be in communication with the portable platform via wireless means.
In a preferred embodiment, the cameras (120 and 121) are
temporarily stored in the portable platform (123 and 207) in one of
the storage spaces (220A or 220B or 220C or 220D or 220E-224). In
the preferred embodiment a sensor communication link (112) with
cameras (120, 121) and power for cameras (120, 121) is provided
through one of the connection ports such as general purpose ports
(206A, 206B) or alternate connector port (208C). An alternative
communication and power connection for cameras (121, 120) is the
PCMCIA card interface (211). Such connections between cameras (120,
121) and the portable platform (123 and 207) are examples of sensor
interfaces.
A preferred embodiment for a dynamic sensor (119) is a
piezoelectric transducer such as a single- or tri-axial
accelerometer. Many other dynamic signal analysis sensors can be
used instead. These normally supply 4 to 20 mA signal output
transmitted through sensor communication link (112).
Alternative dynamic signal measurement devices to the vibration
sensor (119) include the sonic sensor (118), ultrasonic sensor
(117), flux sensor (115), or current sensor (114). One example
includes both sonic and ultrasonic measurements. This device
measures decibel values including peak value, peak hold, and
average in selected frequency sonic and ultrasonic frequency ranges
which are typically 4 kHz, 30 kHz, and 40 kHz. Another example of a
sonic sensor is a microphone. An example of a flux sensor is a
current frequency clamp.
Power may be supplied from the portable platform (123 and 207) to
the sensor(s) (114, 115, 116, 117, 118, 119, 120, 121) through the
sensor communication link (112). This power may be temporarily
supplied for purpose of recharging battery or may be supplied for
the entire time the sensor is in use. For wireless applications
using sensor communication link (112) the sensor (114, 115, 116,
117, 118, 119, 120, 121) normally uses it's own battery power which
may or may not be recharged by the portable platform (123 and
207).
Sensor ports (208A, 208B) on the portable platform (123 and 207)
may include features that provide one-way or two way data transfer
between the portable platform (123) and one or more sensors (114,
115, 116, 117, 118, 119, 120, 121), power management and sensor
signal interpretation for sensor(s) (114, 115, 116, 117, 118, 119,
120, 121). Sensor ports (208A, 208B) are examples of sensor
interfaces.
Optional accessories used in conjunction with dynamic signal
analysis include a speed sensor, a tachometer, or a strobe.
In preferred embodiments, a dynamic sensor (119, 118, 117, 115,
114) is connected through sensor communication link (112) to the
portable platform (123 and 207) via a sensor port (206A or 206B),
which preferably is ruggedized, or via alternate channels such as
general purpose ports (206A, 206B) or communication port (208C), or
to a PCMCIA card in the PCMCIA slot (211). Such connections serve
as sensor interfaces.
When it is not in use, the sensor(s) (114, 115, 116, 117, 118, 119,
120, 121) is(are) stored on the back of the portable platform (123)
in a space provided for that purpose. An alternate embodiment uses
wireless communication (112) between the sensor(s) (114, 115, 116,
117, 118, 119, 120, 121) and the portable platform (123 and
207).
In the preferred embodiment the oil sensor (116) is fixed rigidly
to the lubricating oil system. The oil sensor (116) measures some
aspect of the lubrication system such as oil quality, oil level,
oil contamination, or mechanical wear debris. For example a
capacitive oil sensor can be used to measure the dielectric
permittivity of oil and trigger low oil when the level falls to the
level of the oil sensor (116). An alternative to mounting the oil
sensor (116) in the oil system is to dip the sensor into the
oil.
The oil sensor (116) transmits measurements to the portable
platform (123 and 207) via electrical or wireless connection
(112).
The portable platform (123 and 207) may include optional safety
rating for use in hazardous environments including potentially
explosive atmospheres.
In a preferred embodiment, the portable platform (123 and 207)
includes digital signal processing (DSP), to enable fast
measurement time for greater productivity. Productivity is reduced
by reducing data collection time and simplifying analysis using
high real-time rate, fast auto-ranging, and an extended dynamic
range.
In the most preferred embodiments the portable platform (123 and
207) is small and lightweight so that it can easily be carried up
ladders and into tight areas, even on the longest routes. The
rugged housing will resist damage, and it stands up to harsh
operating conditions. The backlit display and special
electroluminescent keypad eliminate operational problems in dimly
lit areas. For operation in harsh environments, speed enables the
user to obtain quality data with minimal personal exposure.
The portable platform (123 and 207) typically includes a processor
(124), a portable display (125 and 204), a portable power source
(126), one or more data input and data output ports such as
transmitter (127) and general purpose ports (206A, 206B), a field
user interface (111, 200, 201, 202, 203, 205, 212, 213), a portable
database (108), application instructions (109), one or more sensor
ports (208A, 208B), and an alternate connector port (208C).
General-purpose ports (206A, 206B) and alternate connector port
(208C) may be serial ports, USB ports, or custom ports designed
specifically for use in the portable platform (123 and 207). When
connected to the sensor suite (122), the portable platform (123 and
207) is typically in one-way or two-way communication (112) with
the sensor suite (122) through a sensor ports (208A, 208B) using
wired or wireless mechanisms. In alternate embodiments general
purpose ports (206A, 206B) or alternate connector port (208C) may
be used in combination with, or in place of, sensor ports (208A,
208B) for connecting portable platform (123 and 207) to the sensor
suite (122). In such embodiments general purpose ports (206A, 206B)
and alternate connector port (208C) serve as a sensor interface. In
some embodiments the portable platform (123 and 207) may receive
data from sources other than a sensor suite. For example, the
portable platform may be equipped for receiving image data and
sensor data from a network server, from another portable platform,
from a base station, or from another similar source. In the most
preferred embodiments, a primary function of the portable platform
(123 and 207) is capturing imaging sensor data (147A, 147B) and
dynamic sensor data (146A, 146B). In some embodiments the process
of capturing the data includes storing the data in the portable
database (108). The portable platform (123 and 207) may also
communicate with a base station (101) via one-way or two-way data
transfer via electrical contact or wireless mechanisms such as an
appropriate PCMCIA card interface (211). In preferred embodiments
the portable platform (123 and 207) includes at least a transmitter
for data transfer and the base station (101) includes at least a
receiver for data transfer. In some embodiments the process of
capturing data does not include storing the data in the portable
platform (123 and 207); instead the data are transmitted directly
to the base station (101) without storage in the portable platform
(123 and 207). The base station (101) typically also includes a
central processor, which is typically a conventional central
processing unit but in alternate embodiments may be thin client
processor, an application specific integrated circuit, or similar
electronics. The base station (101) generally incorporates station
digital memory, such as read only memory, random access memory, and
media memory such as compact disc data storage. The base station
(101) typically runs application software (106) which controls data
input/output through sensor communication link (112) and (when
used) base communication link (107). The application software (106)
also accepts user input through user interface
One embodiment of the portable platform employs a modified version
of a equipment analyzer which already works in conjunction with a
plurality of dynamic signal sensors including vibration sensor
(119), sonic sensor (118), ultrasonic sensor (117), flux sensor
(115), and current sensor (114). Major modifications to the
equipment analyzer accommodate the preferred embodiment include
more than one sensor ports (208A, 208B), application instructions
(109), and portable database (108), to accommodate the addition of
camera(s) (120, 121) and oil sensor(s) (116).
The preferred embodiment for the portable platform employs carrying
straps attached to slots (209A, 209B, 209C, 209D) on the portable
platform.
In the preferred embodiment a portable display (125, 204) is a
transflective, color, liquid crystal display with selectable
backlighting. One optional configuration is to use a touch-screen
display. Another optional configuration is a microphone (213) for
sound recording at least voice information when using the portable
platform (123 and 207). Still another optional configuration
includes a speaker (214) for audio output.
In some embodiments it is envisioned that the portable platform
(123 and 207) or base station (101) might include voice recognition
and/or text-to-voice features to facilitate expanded user
interface.
In the preferred embodiment the portable display (125) functions as
part of the user interface (111) providing visual communication to
the user in the field. An optional configuration includes
microphone and speaker so that the video interface is supplemented
with audio output and sound recording for voice annotation.
The preferred embodiment uses rechargeable batteries to provide
portable power (126) to operate the portable platform (123) and may
also be used to power sensor(s) (114, 115, 116, 117, 118, 119, 120,
121).
Transmitter (127) is used to provide data output through
electrical, wireless, visual, and possibly audio means. Sensor(s)
(114, 115, 116, 117, 118, 119, 120, 121) connect to the portable
platform by electrical or wireless mechanisms.
In the preferred embodiment the portable database(s) (108) is(are)
derived from that(those) used in a equipment analyzer with
additional support as needed to accommodate visible and infrared
cameras (120, 121) and oil sensor(s) (116). An alternate embodiment
is to employ all of the database elements into the portable
database. This database already supports imaging and dynamic signal
analysis data sources, but generally requires modification to
operate on the processor (124) rather than the central processor
(102) as part of the optional base station (101). In this alternate
embodiment, replication or a similar concept may be used to
synchronize the portable database (108) with the stationary
database (105) which may also be a derivative of the stationary
database (105).
In the preferred embodiment the application instructions (109)
operate on the portable platform (123,207) enabling embedded
intelligence, fast data collection, advanced bearing analysis using
stress wave analysis methodology, reliable slow speed measurements,
single or dual channel or multi-channel analysis, balancing, laser
alignment, cascade, transient analysis, motor monitoring, imaging,
and thermography. The user is directly notified about the nature of
a developing fault at the time of measurement. This enables the
user to focus attention on critical machine issues as soon as they
are identified and collect additional diagnostic information while
still at the machine site.
In the preferred application instructions (109) embodiment the user
can choose from a menu of special tests and it automatically
configures itself for collecting additional data to focus in on the
problem.
Optional features for the application instructions (109) include
demodulation, used for early detection tool due to its ability to
isolate specific fault frequencies associated with the developing
bearing or gear fault; and stress wave analysis, which goes beyond
demodulation's ability to identify the fault by providing an
objective, trend suitable measure of the fault severity.
In one embodiment the application instructions (109) includes
advanced digital technology to detect the stress waves generated by
faults such as fatigue cracking, cracked gear teeth, abrasive wear,
scuffing, or impacting in their earliest stages. The early and
accurate detection provided by stress wave analysis results in
improved maintenance planning, enabling the user to lower costs,
decrease downtime, and reduce spare parts inventory.
In one embodiment the application instructions (109) includes slow
speed technology to take reliable readings with single or even dual
integration as low as 10 RPM.
In one embodiment the application instructions (109) includes
cascade analysis which quickly captures a series of FFT spectra
during startup or coast-down, which can be displayed as a waterfall
plot. It can also be used for short-term continuous monitoring of
critical machine problems.
The application instructions (109) and portable platform (123 and
207) may support dual channel capability which can reduce data
collection time by as much as 50%. The productivity gains alone
typically justify the investment. Far beyond productivity
improvements, the dual channel analyzer opens up new analysis
possibilities to confirm faults such as misalignment, looseness,
cracks, and structural resonance. The dual channel analyzer also
provides filtered orbit analysis. The dual channel dynamic signal
analyzer includes the advanced cross-channel program as a standard
module to determine the root cause of a failure. Embedded
intelligence makes cross channel analysis easy to use with minimal
training. The companion software can be used to analyze and archive
the results, plus provides a custom data export link to operating
deflection shape and modal analysis software.
Optional application instructions (109) programs are available for
the dynamic signal analyzer may be used for transient, balancing
and laser alignment. The optional advanced transient program turns
the dynamic signal analyzer into a single or dual channel digital
tape recorder with full analysis capabilities.
Another optional application instructions (109) program supports
the analyzer being used for shop or field balancing. In a
particular embodiment the graphical interface makes operation
simple and helps avoid the typical errors made in balancing setup.
The program systematically removes background vibration while the
balancing watchdog expert alerts the user to other conditions that
could complicate the balance job.
The application instructions (109) supports imaging and image
analysis. In the preferred embodiment this includes visual imaging,
thermal imaging. Optional thermographic image analysis includes
display of radiometric images in selectable modes including
grayscale, ironbow, rainbow, and/or other pallets. Typically the
display field also includes a legend depicting temperatures to
which colors and shades correspond. The user normally selects one
or more points for which actual temperature is displayed in text as
well as pixel color/shade. Stored images and video clips can be
recalled for display, annotation, and editing in the field. Such
images and video clips are examples of imaging sensor data.
The application instructions (109) used in the preferred embodiment
supports watch variable data collection including notes and
observations representing visual, audible, and otherwise perceived
observations logged by the technician using the portable
platform.
Each sensor port (208A, 208B) included in the portable platform
(123 and 207) is configured to one or more of the array of sensors
in the sensor suite (122). In most embodiments this includes signal
interpretation. It typically also includes mechanisms for
attachment and transport of the one or more sensors when it or they
is or are not in use, and sensor communication (112) with each
sensor during use. It may also include power supplied to the
sensors for the purposes of either measurement or recharging sensor
batteries.
Connection between the portable platform (123 and 207) and the
sensor suite (122) includes physical connection and data
communication. In one embodiment physical connection and
communication to the sensors makes use of one or more ports such as
PCMCIA card interface (211). In another embodiment communication is
wireless using either radio frequency or infrared data transfer
mechanisms. Sensors may be attached to the portable platform (123
and 207) in a convenient location such as on the back of the
analyzer package (220A or 220B or 220C or 220D or 220E).
One optional embodiment includes a feature enabling printing to be
accomplished directly from the portable platform (123 and 207).
Typically this is done using application instructions to format the
signal with printer instructions. Communication to the printer may
be made through a printer port (210) or via wireless means or
directly to an integral printing device.
Optional connection between the portable platform and the base
station (101) is provided for the broadest application of this
invention. In the preferred embodiment, the base station (101) may
include these elements: computer operating system (143), receiver
(104), stationary database (105), computer display (142), central
processor (102), application software (105), and connection and
base communication link (107) to the portable platform. The
computer operating system (143) is typically Microsoft Windows.RTM.
or Microsoft Windows CE.RTM., although other operating systems may
be used. The central processor (102) is typically a desktop central
processing unit. The base communication link (107) may be wired or
wireless. The base station is an optional embodiment because all of
these functions could be performed in the portable platform if one
desires. One may prefer to maintain a stationary database (105) and
all that goes with it to provide greater integration with other
asset management database and software applications, to provide
multi-user network, to provide memory backup, to provide extended
memory and analysis tools, to allow the user to perform final
analysis and reporting functions in a comfortable location, to
allow others ready access to the information, for fuller
integration with systems, and for other individual reasons.
A standard desktop CPU is preferred as the central processor (102)
in the base station (101), although other devices such as an
application specific integrated circuit (ASIC) may be used.
In the preferred embodiment, the printer (103) is in communication
with the central processor (102) as part of the base station (101)
system. Typically the printer drivers are provided with the base
software (106) although one could easily connect or incorporate or
simply communicate the printer, when used, directly with the
portable platform (123 and 207).
The printer (103) is one way to report results. Other, equally
acceptable methods include electronic reporting via file transfer
using data files or PDF style reports or other style reports. An
alternate reporting method is email messaging or voice mail
messaging or display messaging or other ways to let the intended
recipient know about data and information derived from sensor
inputs and personal observations.
There are many embodiments for the receiver (104) on the base
platform (101) including devices using file transfer protocol,
replication, serial communication, manual data entry, and others.
The base communication link (107) can include physical connection
or wireless connection between the base station (101) and portable
platform (123 and 207). This base communication link (107) may
include linkage through an Ethernet or internet or intranet or
other network.
The preferred embodiment for base station software and stationary
database are extended versions of commercially available
reliability software (106) and stationary database (105). Logical
upgrades to these commercially available tools are required to
support the invention. An alternate embodiment uses similar
software and database structure on both the portable platform (123
and 207) and base station (101), including replication or another
method for synchronizing database information between the two
systems. Another alternate embodiment uses wireless Ethernet or
similar communication through the base communication link (107)
such that the stationary database (105) receives data directly or
shortly after it is collected in the field. In this case the
portable database(s) (108) can be very small or nonexistent since
the data is being directly stored onto the base station (101).
One can envision that by using Ethernet or internet or other
on-line communication as at least part of base communication link
(107) between the portable platform (123 and 207) and base station
(101) that the distinction between base software (106) and
application instructions (109) can shift such that the base
software can supplement or replace or update the functions
envisioned in this invention for the application instructions
(109). In the same way, the database functions may be performed in
the stationary database (105) or the portable database (108) or
some combination of both.
By using base communication link (107), some or all of the software
functions (106 and 109), the database functions (105, 108), and
optional printer function (103), and even functions of the sensor
ports (208A, 208B) may be performed using either the portable
platform (123 and 207) or the base station (101) or some
combination of both.
A physical embodiment of a portable platform is depicted in FIGS. 2
and 3 as portable platform (207). FIG. 2 portrays the front (or
top) of the portable platform (207), and FIG. 3 portrays the back
(or bottom) of the portable platform (207). A display (204)
performs a plurality of functions including display of header
information (205) for location, equipment information, summary, or
other information used to orient the user to the type of
information on the remaining portions of the display. Another
function of the display (204) in the preferred embodiment is the
allocation of one or more windows (203A, 203B, 203C, 203D) of the
display (204) to reporting measurements, images and graphics to
facilitate translating measured data into useful information. In
this application, a window refers to any pop-up or overlay or
highlighted area or sector or portion or otherwise set-aside
vicinity of the display in which a particular function is
performed. The windows (203A, 203B, 203C, 203D) of the display
(204) may depict vibration spectrum, vibration waveforms, bar
graph, visual images, trend plots, tabular data, setup information,
etc.
These display windows (203A, 203B, 203C, 203D) are easily adapted
for dynamic signal analysis and for imaging analysis functions.
Functions historically performed on the display of an infrared
camera may be performed on the display windows (203A, 203B, 203C,
203D) including but not limited to the following list: live thermal
image, live visual image, frozen visual image, frozen thermal
image, text annotation, graphic annotation, temperature at cursor
points, temperature histogram, temperature profile, alarms,
parameters, user instructions, etc. Functions historically
performed on the display of a dynamic signal analyzer may be
performed on the display windows (203A, 203B, 203C, 203D). These
include but are not limited to active waveform, active spectrum,
individual waveform, individual spectrum, trend, data table,
alarms, parameters, graphic representation, dynamic or frozen modal
analysis, demodulated spectrum or waveform, cascade, transient,
etc.
Another display function in the preferred embodiment it to provide
dynamic or changeable function selections (212) corresponding to
function keys (200). In the case of a touch-screen display (204)
the function keys (200) might be combined with function key
descriptions (202).
Preferred embodiments use sensor ports (208A, 208B) for data input
and output from sensors. Alternately other ports such as the PCMCIA
card interface (211) or even printer port (210) may also be used.
The preferred embodiment provides for user supplied data input
through field user interface (111 in FIG. 1) and output through the
portable display (204). In preferred embodiments, field user
interface (111) includes dynamic function keys (200), function
descriptions (202), keypad interface (201), changeable function
selections (212), display windows (203A, 203B, 203C, 203D), header
information (205), and microphone (213). The user may also provide
input via one or more of the sensor (114, 115, 116, 117, 118, 119,
120, or 121 in FIG. 1) in communication with the portable platform
through the portion of the sensor communication link (112 in FIG.
1) serving such sensor(s).
The portable platform (123 and 207) is substantially contained in a
housing (215). One or more strap slots (209A, 209B, 209C, 209D) may
be provided in the housing (215) to facilitate attaching one or
more carrying straps to the platform, or to facilitate tie-downs
for retaining the portable platform in a fixture or carrying
case.
FIG. 3 also illustrates 5 storage spaces (220A or 220B or 220C or
220D or 220E, 221, 222, 223, and 224). These spaces are recesses in
the back/bottom of portable platform (123 and 207) which are
specifically dimensioned to hold sensors or other accessory devices
used with the portable platform (123 and 207).
An example of an application of embodiments is depicted in the
switchyard diagram of FIG. 4. Various components of the switchyard
are depicted. These are (from right to left) high voltage
transmission lines (255), disconnect (254), transformer (253),
potential and current transformers (252), circuit breaker (251),
and low voltage transmission lines (250). Table 1 shows how a
portable platform with multiple sensor technologies may be used to
inspect a switchyard.
TABLE-US-00001 TABLE 1 Inspection of switchgear with an integrated
system. Sensor Applicability Oil Component IR Visible Ultrasonic
Vibration Analysis Power line Yes Yes Yes No No Connection Yes Yes
Yes No No Insulator Yes Yes Yes No No Bushing Yes Yes Yes No Yes
Junction Yes Yes Yes No No Coupling Yes Yes Yes No No Disconnect
Yes Yes Yes No No Current transformer Yes Yes Yes No Yes Disconnect
Yes Yes Yes No No Main transformer Yes Yes Yes No Yes Load tap
changer Yes No Yes No No Breaker Yes Yes Yes No Yes Operating
status Yes Yes No No No Cooling system Yes Yes No No No Motor Yes
Yes No Yes No Pump Yes Yes No Yes No Gas compressor Yes Yes Yes Yes
Yes
Table 1 presents a matrix of different combinations of sensors that
may beneficially be employed to measure the health of particular
components in an electrical switchyard. Various embodiments may be
used to check each of the components listed in each row of the
Table 1 by incorporating sensor capability identified in the
columns where "yes" is listed in that row. Matrix elements labeled
"No" indicate that the sensor in that column is generally not
applicable for inspecting the component in that row. However, under
special circumstances such use may be appropriate.
FIG. 5 illustrates a method embodiment of the invention. The method
begins with a storing application instructions in an instrument
step (302). Then two additional processes are conducted. One of
these processes involves a receiving and storing imaging sensor
data in the instrument step (304) followed by a deriving imagery
indication of equipment health step (306). The other of these two
additional processes includes a receiving and storing dynamic
sensor data in the instrument step (308) followed by a deriving
dynamic indication of equipment health step (310). It is cautioned
that while FIG. 5 might incorrectly be interpreted to show that the
two additional processes are conducted in concurrently in parallel,
the two additional processes do not necessarily have to be
conducted concurrently in parallel (although they may be). For
example, the receiving imaging sensor data in the instrument step
(304) and the deriving imagery indication of equipment health step
(306) may be completed before beginning the receiving dynamic
sensor data in the instrument step (308) and the deriving dynamic
indication of equipment health step (310), or steps (308) and (310)
may be completed before beginning steps (304) and (306).
Alternately, the receiving imaging sensor data in the instrument
step (304) may be conducted first, followed by the receiving
dynamic sensor data in the instrument step (308). Using the reverse
sequence of those two steps is also possible. However, the deriving
imagery indication of equipment health step (306) must be preceded
(although not immediately preceded) by the receiving imaging sensor
data in the instrument step (304), and the deriving dynamic
indication of equipment health step (310) must be preceded
(although not immediately preceded) by the receiving dynamic sensor
data in the instrument step (308). After the deriving imagery
indication of equipment health step (306) and the deriving dynamic
indication of equipment health step (310) are completed, the step
(312) of correlating imagery indication of machine health with
dynamic indication of machine health may be undertaken and
completed.
FIG. 6 illustrates a different method embodiment of the invention.
The method begins in a manner similar to the method of FIG. 5 with
a storing application instructions in an instrument step (322).
Then two further processes are conducted. One of these processes
involves an acquiring imaging sensor data with an imaging sensor
step (324), followed by a receiving and storing imaging sensor data
in the instrument step (326) followed by a deriving imagery
indication of equipment health step (326). The other of these two
further processes includes acquiring dynamic sensor data with a
dynamic sensor step (330), a receiving and storing dynamic sensor
data in the instrument step (332), followed by a deriving dynamic
indication of equipment health step (334). As with FIG. 5, the two
further processes do not have to be conducted concurrently in
parallel. Steps (324), (326) and (328) may be completed before
beginning steps (330), (332) and (334), or vice versa. Alternately,
the acquiring image data with an imaging sensor step (324) may be
conducted first, followed by the acquiring dynamic sensor data with
a dynamic sensor step (330). Using the reverse sequence of those
two steps is also possible. However, sequence of steps following
the acquiring image data with an imaging sensor step (324) have to
proceed sequentially (but not immediately) in the order shown, and
the sequence of steps following the acquiring dynamic sensor data
with a dynamic sensor step (330) have to proceed sequentially (but
not immediately) in the order shown. After the deriving imagery
indication of equipment health step (328) and the deriving dynamic
indication of equipment health step (334) are completed, the
correlating imagery indication of machine health with dynamic
indication of machine health step (336) may be undertaken and
completed.
FIG. 7 illustrates a further alternate method, one that
incorporates the use of a base station. The method begins with a
storing application instructions in an instrument step (342) and a
storing application software in a base station step (342). These
steps may be completed in any order. Then two subsequent processes
are conducted. One of these processes involves the step (346) of
capturing imaging sensor data with an imaging sensor operatively
connected to the instrument and using the instrument to transmit
the imaging sensor data to the base station, followed by the step
(348) receiving and storing the imaging sensor data in the base
station, followed by the step (350) of deriving imagery indication
of equipment health in the base station. The other of these two
subsequent processes includes the step (352) of capturing dynamic
sensor data with a dynamic sensor operatively connected to the
instrument and using the instrument to transmit the dynamic sensor
data to the base station, followed by the step (354) of a receiving
and storing dynamic sensor data in the base station, followed by a
deriving dynamic indication of equipment health step (356). As with
FIGS. 5 and 6, the two subsequent processes do not necessarily have
to be conducted concurrently in parallel. However, sequence of
steps following the step (346) of capturing imaging sensor data
with an imaging sensor and transmitting the imaging sensor data to
the base station have to proceed sequentially (but not immediately)
in the order shown, and the sequence of steps following step (352)
of capturing dynamic sensor data with a dynamic sensor and
transmitting the dynamic sensor data to the base station have to
proceed sequentially (but not immediately) in the order shown.
After the step (350) of deriving imagery indication of equipment
health in the base station and step (356) of the deriving dynamic
indication of equipment health in the base station are completed,
the correlating imagery indication of machine health with dynamic
indication of machine health step (358) may be undertaken and
completed.
The foregoing description of preferred embodiments for this
invention have been presented for purposes of illustration and
description. They are not intended to be exhaustive or to limit the
invention to the precise form disclosed. Obvious modifications or
variations are possible in light of the above teachings. The
embodiments are chosen and described in an effort to provide the
best illustrations of the principles of the invention and its
practical application, and to thereby enable one of ordinary skill
in the art to utilize the invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. All such modifications and variations are within the
scope of the invention as determined by the appended claims when
interpreted in accordance with the breadth to which they are
fairly, legally, and equitably entitled.
* * * * *
References